Wire Electric Discharge Machining of Metal Matrix Composite Materials

Shandilya, Pragya; Jain, Pushpendra Kumar; Jain, Nikhil

doi:10.2507/daaam.scibook.2011.30

Cited by 12 publications

(7 citation statements)

References 14 publications

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“…It can also be observed from the micrograph shown in Figure 6 that machined surface has little presence of reinforced particles and these are clustered below the machined surface. These results are also in conformance with those reported on the machining of Al-Li/SiC composites [18]. The formation of clusters or uneven distribution of reinforced particles deteriorates the strength of the machined surface.…”

Section: Relationship Between Recast Layer Thickness With Pulse Durat...supporting

confidence: 91%

Electric Discharge Machining of 10 vol% Al2O3/Al Metal Matrix Composite - An Experimental Study

Sidhu

Kumar

Batish

2013

MSF

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The particle reinforced metal matrix composite have hard particles dispersed in matrix which make them difficult to machine with conventional machining methods. Electric discharge machining (EDM) is an effective tool for machining such materials. This experimental study was undertaken to identify the significant factors that affect the output responses while machining of 10 vol%Al2O3/Al composite material. The material removal rate (MRR) and tool wear rate (TWR) have a direct relationship with current and an inverse relationship with pulse on-time. Appropriate levels of current and pulse on time levels can be chosen while roughing and finishing operations. Normal polarity between terminals had higher MRR than with reverse polarity. The recast layer had a non-uniform and wave-like morphology and cracks penetrated into the matrix phase resulting in high residual stresses exceeding the ultimate tensile strength of the material. Pulse on-time has greater influence on recast layer thickness than current. The reinforced particles were all clustered under the machined surface with very few in the recast layer which results in a low strength of the machined surface. The presence of reinforced particles in recast layer is very rare, so it is desirable to remove it. Keywords: electro-discharge, machining, aluminum matrix composites, material, removal, tool, wear, roughness, recast, layer

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Section: Relationship Between Recast Layer Thickness With Pulse Durat...supporting

confidence: 91%

Electric Discharge Machining of 10 vol% Al2O3/Al Metal Matrix Composite - An Experimental Study

Sidhu

Kumar

Batish

2013

MSF

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“…Shandilya et al (2010) concluded that to achieve higher value of the average cutting speed, lower value of voltage and higher value of pulse-off time should be used during WEDC of SiCp/6061 Al MMC. Shandilya et al (2011) investigated the effect of input process parameters such as servo voltage, T ON , T OFF and wire feed rate on MRR and kerf during WED machining of SiCp/Aluminum 6061 MMC. Response surface methodology (RSM) was used to analyse the experiments.…”

Section: Wire Electric Discharge Machining (Wedm)mentioning

confidence: 99%

Machining of Metal Matrix Composites by EDM and its Variants: A Review

Bisaria¹,

Shandilya²

2015

DAAAM International Scientific Book 2015

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Nowadays the keen interest of the automobile and aerospace sector on metal matrix composites (MMCs) is increasing due to is attractive mechanical properties and applications. The machining of MMCs by advance machining process is the relatively new field of attention for researchers and scientist as conventional machining of MMCs is complex and difficult. Electric discharge machining (EDM) is widely used process among advance machining process for machining MMCs. This research work investigates different variants of EDM for machining the wide range of MMCs. The effect of process parameters (spark gap, pulse current, duty cycle etc.) on response parameter such as material removal rate (MRR), tool wear rate (TWR), surface finish (SR) etc. during the machining of different MMC martials with different variants of EDM were studied under this review paper.

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“…The primary processing parameters of WEDM include applied voltage, flushing pressure (FP), pulse on and off time, wire feed (WF) rate, dielectric medium, etc. [21]. Manually, optimizing all the processing parameters requires a large number of experiments, which is a tedious and timeconsuming process.…”

Section: Introductionmentioning

confidence: 99%

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Kumar¹,

Prasanna²

2022

Materials Science-Poland

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The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiC g ) and black SiC (SiC b ) particles. The WEDM machining parameters, such as pulse on time (TON ), wire feed (WF) rate, and flushing pressure (FP) of the resultant stir cast AA6063/SiC b and AA6063/SiC g composites, were optimized using the Taguchi method with L9 orthogonal array to estimate the responses, such as surface roughness and metal removal rate. Further, through grey relational analysis, the finest parameters for WEDM of AA6063/SiC b and AA6063/SiC g composites were evaluated as TON = 50 μs, WF rate = 18 m/min, and FP = 3 MPa. With the optimum parameters obtained, conformational experiments were conducted, and the scanning electron microscopic images were recorded, along with the energy-dispersive X-ray (EDX) spectroscopic data of the worn surfaces and debris. From the EDX mapping images of the machined surface, it was evident that AA6063/SiC b displays a more polished surface than AA6063/SiC g . However, for applications requiring a high metal removal rate, AA6063/SiC g displays better results than AA6063/SiC b .

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Wire Electric Discharge Machining of Metal Matrix Composite Materials

Cited by 12 publications

References 14 publications

Electric Discharge Machining of 10 vol% Al<sub>2</sub>O<sub>3</sub>/Al Metal Matrix Composite - An Experimental Study

Electric Discharge Machining of 10 vol% Al<sub>2</sub>O<sub>3</sub>/Al Metal Matrix Composite - An Experimental Study

Machining of Metal Matrix Composites by EDM and its Variants: A Review

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

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